Mumbai's Thane Borivali Twin Tunnel Work Speeds Up Cutting Travel Time
Construction on Mumbai’s ambitious Thane–Borivali Twin Tunnel Project has accelerated, with key civil works nearing completion. Once operational, the 11.8-kilometre twin tunnel will cut travel time between Thane and Borivali from nearly 90 minutes to just 15, reshaping connectivity across the Mumbai Metropolitan Region (MMR).
Undertaken by the Mumbai Metropolitan Region Development Authority (MMRDA), the project is the country’s largest urban tunnel road initiative. It will connect Thane’s Ghodbunder Road with Borivali’s Western Express Highway through the Sanjay Gandhi National Park one of the few remaining green lungs in Mumbai.
MMRDA officials confirmed that the excavation of the launching shaft in Thane, which began in October 2024, is now in its final stages. The Thane casting yard is fully operational, while land acquisition is nearly complete. Rehabilitation of families affected by the project in Borivali has also commenced, ensuring that social and environmental safeguards remain integral to the execution process.
The project uses advanced Tunnel Boring Machines (TBMs) Nayak and Arjuna supplied by Herrenknecht India.
These high-precision machines are designed to minimise ecological disruption, an essential requirement given the tunnel’s route under the protected forest zone of Sanjay Gandhi National Park. Engineers note that the use of TBMs reflects a shift toward cleaner, more sustainable construction practices in India’s urban infrastructure projects.Each tunnel will feature two traffic lanes and one emergency lane, with cross-passages every 300 metres for safety. The design also includes systems for smoke detection, LED signage, fire suppression, and ventilation to ensure a safe and comfortable commuter experience.
Transport experts believe the twin tunnel will significantly decongest Mumbai’s northern suburbs. “This corridor will change how the city moves,” said an urban mobility planner. “It will not only reduce travel time but also lower vehicular emissions from idling traffic on surface roads.”Once operational, the tunnel is expected to divert thousands of vehicles daily from Ghodbunder Road and the Western Express Highway, easing congestion and improving air quality. Officials estimate substantial fuel savings and reduced carbon emissions as a result of smoother traffic flow and shorter travel distances.
Beyond its transport benefits, the Thane–Borivali Twin Tunnel aligns with Mumbai’s broader vision for sustainable mobility and resilient infrastructure. By integrating technological efficiency with environmental safeguards, the project exemplifies how Indian cities are adapting to the challenges of urban expansion while prioritising ecological balance.As the MMRDA targets steady progress through 2025, the tunnel is poised to become a symbol of Mumbai’s evolving infrastructure one that connects communities, conserves nature, and redefines what sustainable urban connectivity can achieve.
